Nervex Professional Lugs

Until
the advent of the Nervex Professional lugs many framebuilders cut their
own trademark lugs in-house. This was obviously very
time-consuming and relatively expensive. Before the
Professional many companies, including Nervex, produced pressed
steel
lugs of various designs which were used some as produced and some
modified.

The Professional though was a classic design
destined to succeed from the day it was introduced. The lug
just looked right, beautifully cut with pleasing lines and not needing
to be over-elaborate as some lugs could be. Also, these pressed-steel
lugs were relatively light and well finished, apparently needing less
filing and cleaning-up than some of the cast steel designs available at
the time.

Frame builders took to it at once and more importantly, so did the
public. Part of its success can be attributed to Nervex lugs being
chosen by many of the top frame builders and racers on the continent;
Louison Bobet reportedly won the 1950 French Road National Championship
on a Stella frame built with a Nervex Pro lugset. Naturally, the Brits
wanted the same equipment on their machines.

The Nervex Professional lugset is now
considered a classic design yet
it was remarkably prolific. Throughout the 1950s and 1960s almost every
frame maker used Nervex Pro lugs at some time or other and this was
equally true of exclusive frame makers (Gillott,
Bates, Ephgrave, Jack Taylor, De Rosa, Colnago, Bianchi, Masi - and
many others) to the mid sized (Viking, Dawes, Holdsworth, Carlton,
Mercian) and even the largest mass producers (Raleigh, Peugeot, and
Schwinn and Paramount in the USA). It might be imagined that
the mass-production of these lugs might diminish their significance as
a classic item. This has clearly not been the case.

Nervex
Professional seen here (and above right) on 1955 Gillott -
this
has the later version of the lugs and the centre/front of heads have
been filed to give a finer profile to the 'fishtail'

The Different Types

The first
Nervex Pro lugs were produced with a vary fine pair of
‘horns’ at the centre-front of the two head lugs.
Later on the lugs were changed slightly and the
‘horns’ (left) were replaced by a
‘fishtail’ (right). This newer design was certainly
in use by 1955 although the earlier style was still used by some frame
makers for some time after, presumably because lugs were often bought
in boxes of 50 or more, and these would take time to be used up.
Nervex developed and produced their range of lugs in
the post- WWII years, late 40s, but the first time they were imported
to
the UK seems to be around 1950.
As well as the early and later type lugs, there were also differences
in the detailing. Almost all lightweight frame builders would lighten
and clean up the lugs to some extent, usually filing them to feather
the edges, but often the edges themselves were filed to produce a
crisper and better defined shape. Comparing similar Nervex Pro lugs on
a 1962 Viking, a 1986 Mercian and 1955 Gillott machines, it
is clear that the Gillott has better detailing. This is most apparent
in the shape of the 'fishtail' on the Gillott head lugs. The 'V' in the
centre of the fishtail is deeper and has better definition. On the
other hand, it is quite possible that the standard of finish
of Nervex pressings may have diminished over the years, thereby
offering a different explanation a to the higher quality of the Gillott.

1955 Gillott

1962 Viking

1986 Mercian

Other changes amongst different frame makers centre on modifications to
the lugs themselves. Clearly, the more highly-regarded frame makers
would not want their own products to be the same as anyone elses. In
order to achieve this they would often modify Nervex Pro lugs either by
cutting away parts or making 'windows' in the lugs (such as the
Ephgrave No 2 lugs), or by adding spearpoints or other shapes
(Holdsworth used this technique on certain models).
The Nervex Professional was
produced with a strenghtening rib at the top and bottom edge of the
headlugs. This rim can be seen on the lugs to the right
(Bates).
Several framebuilders considered this an unnecessary
feature and felt that it detracted from the simplicity of the
lug. When a frame is well built the top and bottom
faces of the head lugs are ‘faced’ to give perfect
alignment to the bearings.
This took a sliver off the rib
anyway so many builders filed the rest of the rib away and polished it
into the the face of the lug as can be seen below left.

One aspect that is quite remarkable about the Nervex Pro design is that
it remained popular for such a long time. It appears to have been in
use by 1950 yet it was still available on Mercian frames as late as
2004 - the King of Mercia model could be ordered with Nervex
Professional lugs for an additional £45 in that year,
although they had very few sets left.

Nervex Legere lugs and frame parts
No mention of Nervex lugs would be complete without reference to the
Nervex Legere series lugs, of which there were reportedly more than
forty variations. Again, Legere lugs were prolific amongst English and
European frame makers and some of the Legere designs clearly had a
family resemblance to the Pro series. However, although the Legere and
Pro lugs were both of pressed steel to 'an exclusive process', the
Professional lugs were listed at almost double the price. The 1961
catalogue produced by the UK importer Evian GB lists the
Legere lugs at eight shillings a set (when ordered in a box of
50) whereas the Pro lugs were fourteen shillings and
threepence (or eighteen shillings including the Nervex Pro fork crown).
Quite why there is such a large price difference is not clear; the Pro
series is not that much more complicated in design. It may be that the
steel used for the lugs and/or the bottom bracket shell was of a higher
grade. If you have the answer, please let us know.

Incidentally, a complete set of Nervex lugs included two head lugs, a
seat tube lug, a bottom bracket shell and a Nervex transfer. The
company also supplied many other frame building parts including fork
ends, pump pegs, fork crowns, cable guides etc. The high extra cost of
the Pro fork crown explains why this item was rarely used.

On the right is an example of a Nervex Professional lug as modified by
the builders, Hawkes of London.
The front of the lugs have neither the telltale 'fishtail'
nor
the 'horns'. The lug has been carefully re-profiled to
produce a
simple curve.

A
future for Nervex
Pro lugs
Although the Nervex Professional lugset has been out of production for
many years now its status can be judged by the fact that in the USA
production of an almost identical lug, the Newvex lugset, with a name
so similar you have to look twice to see the difference, seems to be
heading for success. It is not identical, however, as it has been
designed for oversized tubing and also has an 18mm projection at the
top of the head lug.

New unused sets of the original French-made Nervex Pro lugsets
occasionally resurface from the depths of old workshops and sheds from
time to time so frames are still being built today with these lugs -
more than fifty years after they were first produced. It is a lugset
that has stood the test of time and few would argue that it looks as
attractive today as it did back in the days when the Continental stars
were winning races on Nervex Pro eqipped machines in the 1950s.

Technical Jottings
on Nervex lugsBy Peter BrueggemanSome
useful termsFor
Nervex lugs, the feature cut of a lug or lug set refers to
the head lugs, and is seen at the front and sides of the head lugs on
the head tube. The nozzle cut of a lug or lug set is seen
where the down tube, top tube, and seat tube enter a lug, whether head
lug, bottom bracket, or seat lug.

From an October 1958 Nervex
catalogue from Evian (GB) Ltd, "To reference the 'model' of lug set...
select the feature cut and this will form the first part of the
reference. Select the nozzle cut and this will be the second part of
the reference. Thus, lugs required with feature cut number 83 and
nozzle cut number 172 will reference as Model 83/172." The 'feature
cut' pattern is seen on the front of the head lugs and the 'nozzle
cut' pattern is seen on the seat lug, bottom bracket, and the downtube
and toptube ends of the head lugs.

The Nervex
Professional lug
set is referenced as model 49/162, with Pattern 49 and Pattern 162
exclusive to the Professional lug set. In this 1958 catalogue, Nervex
Professional feature cut Pattern 49 is comprised of the familiar
fishtail shape at the front of the head lugs and the familiar side
profile of the head lugs. Nervex Professional nozzle cut Pattern 162 is
the familiar profile on the downtube and toptube ends of the head lugs,
and on the bottom bracket and seat lug.

Serie
Legere lugs were
available in stock with several nozzle and feature cut combinations,
and customized combinations from many nozzle and feature cuts were
available on request. Serie Legere lugs were available for a ladies
model
frame. This
catalogue doesn't discuss the manufacture details of the Serie Legere
lugs but it does mention some manufacture details of the
Professional lugs. One could assume by this omission that the Legere
lugs lack these manufacture details noted for the Professional. For the
Professional lugs the catalogue says they are "...made to close
tolerances, and re-inforced at the bends and around the rim of the head
lugs for increased strength. ... the feature cuts
are ...
thinned out ...".

In this catalogue, the
Professional lug set is shown with two different
feature cut fork crowns. One is a "Professional Racing Feature Cut No.
5" fork crown (right);
it is noted in text as having a narrow head and being
for oval fork blades. This fork crown is sixty millimeters
between the fork blades.
The other is a "D/B. Randonneur
Feature Cut No. 7" (left)
"Sport and Tourist" fork crown; it is noted in text as ½
Ballon
(wide head) and being for oval fork blades. The Sport
version of
the Feature Cut No. 7 fork crown is also sixty millimeters between fork
blades but the Tourist version of the Feature Cut No. 7 fork crown is
68 millimeters between the fork blades, seemingly for wider tyre and/or
mudguard clearance. It is assumed from the use
of the word "Professional" that the Professional Racing Feature Cut No.
5 fork crown is exclusive to the Professional lug set. The D/B
Randonneur Feature Cut No. 7 fork crown is displayed among several fork
crown patterns in this catalogue and it is assumed that it is not
exclusive to the Professional lug set due to the lack of the word
"Professional" and its "Sport and Tourist" designation.

The
Professional lug set "is made for Gents frames only," for English and
French tubing sizes, and in four frame design angles: No. 1 with top
angle 75 degrees and bottom angle 58 degrees; No. 2 with top angle 75
degrees and bottom angle 59 degrees 30 minutes; No. 3 with top angle 72
degrees and bottom angle 61 degrees; No. 4 with top angle 72 degrees
and bottom angle 59 degrees 30 minutes. A Nervex Professional lug set
came with a Nervex
Professional frame transfer.

Building a frame
with the Nervex lugs by Norris Lockley (including some
history of the origins)

I am/was a framebuilder and I still do have several
full sets of these lugs in stock so I am always interested in seeing
what other builders think of them and how they have adapted them. This
article is sent to add a little bit of the historical background to the
company and the development of the Series Mk1 and II of the
Nervex Pro set.

In the late 40s and early 50s most British
framebuilders relied upon cast lugs with which to build their frames.
These could be from English manufacturers such as Vaughan, Davis,
Brampton, Chater Lea etc or from European manufacturers such as
Aerts, or EKLA. As the European economy picked up
after WWII supplies of more modern lugs started to be imported, most of
which were made from precision pressings of mild steel plate by a
process called "emboutissage". Amongst the very first of
these, and very popular with builders, were the excellent
Oscar Egg "Super Champion" models. By about 1953 builders such as JRJ
in Leeds (later to become Bob Jackson cycles) were
also offering the Nervex range of lugs as an option to these
other brands. JRJ also offered, as did several other builders that I
know of, the Franco-Suisse range.

I
started helping a frame-builder in about 1953/54 and up until that time
I had not heard of Nervex lugs, but was aware of Franco-Suisse. My
recent research, as demonstrated by the Franco-Suisse advert,
from February 1950 (see
image left), indicates that in fact the two
brands were one and the same, Franco-Suisse, a firm in St Etienne,
France, being the manufacturer, and Nervex being the brand of lugs that
it manufactured.

It would appear from further research that Ste Franco-Suisse either
sold out to, or changed its name to Francolam, the name that appears on
the box of lugs in the main Nervex article, and on the cover
of the much-quoted and referred-to Nervex lug and parts
catalogue for 1957.

Although the Nervex Pro MkII lug set, with its
fish-tail design, has proven popular for the best part of
fifty years, the fork crown, with its two short prongs, has
not caught cyclists' imaginations to the same extent. It is
only in the last ten years that I have actually bought some of these
crowns as NOS, and so I have no idea how much they cost originally. My
own theory about their lack of popularity is that the crown was an
early pressed model made by Franco-Suisse, to match up with the head
lugs of the Pro MkI lugset, that also had two short spikey prongs.
Whether or not what is now referred to as the Nervex Pro Mk I lugset
was actually at the time known as the Franco-Suisse, I can only
conjecture. Perhaps the Nervex Pro Mk II with the fish-tail feature was
the first lug produced by Francolam and marketed under the Nervex name.
I doubt that we will ever know the full story

The Pro crowns are in a sense a triumph of
"emboutissage" but the method of manufacture did create two gaping
cavernous holes inside the crown that it would have been impossible to
fill with brazing alloy. Even a well-brazed crown would only have line
contact around the perimeters of the holes and along the fancy cut-out
and tangs resulting in a somewhat weak construction. On the
other hand, around the early 50s, companies such as EKLA and Wagner had
started producing very strong accurately cast steel models that gave
full contact areas for brazing between the column, fork blades and the
crown itself. Any self-respecting frame-builder would prefer to use
either cast or forged crowns, they resulted in much stronger and better
performing fork units that were less likely to bend in use or from
which the blends could not work loose due to the lack of brazed area
and contact.

From the frame-building point of view, builders found
the Nervex Pro Mk II set to be very good in that it offered a hand-cut
look without having to expend the time and effort of
drilling and filing, and yet it lent itself to being
altered and embellished in several ways. The other advantage,
one that should not be overlooked, was that the sets were offered in a
variety of angles that either suited frames straight out-of-the-box, or
could be adapted with little effort. The practicality of using
the lug was, however, quite different because, fresh out of
the box, all the lugs needed quite a lot of attention to clean up the
stamped-out curved profiles that often appeared to have been
nibbled rather than cleanly cut. This criticism applied particularly to
the three pipes, i.e. those tubular parts that held the top
and down tubes.

Internally the lugs were very accurate in their angles
and diameters, with very few and only small voids in the junctions
between the upper and lower mitres. The side inner profiles of the
mitres were reamed very precisely, thereby eliminating any sloppiness
of fit. The closeness of internal fit meant more accurate frames and
also the need for less brass to fill voids and less heat to apply it
and to make it run into those voids, i.e. backfilling of the joints.

However this accuracy came at a price, that being that
the pressure applied on the external surfaces by the machines
forming the lugs, often left deepish grooves along the mitres. Some
builders would spend hours filing the whole of the pipes to reduce the
thickness of the metal in attempts to obtain a smoother overall finish,
while others would run lines of bronze welding into the grooves and
then smooth this into the pipes.

The real labour of using Nervex Pro lugs was the time
it took to thin down and taper the pipes either in preparation
before brazing, or afterwards when cleaning up and finish-filing. Those
litte squiggles and swirls, particularly the fish-tails central to the
head lugs, took a lot of skill and care, if a neat and harmoious effect
was to be obtained.

Modified Nervex
Professional lugs:
Some builders would take the Nervex lug, in this case a Professional,
and then re-profile or add brazed-on flourishes. Shown below
are
such lugs from a Holdsworth Whirlwind Special frame. This
frame
would have been built to special order as Holdsworth had stopped
building
frames with fancy lugwork in the mid-60's. By comparing these lugs with
the Professionals above it can be seen where the additions have been
brazed on at the front of the head tube and on the top of the top and
down tubes. Thanks
to Hilary Stone
for images and information.

John Crump's 1950 Mercian 'Viglorelli' with long tangs added to the Nervex Professional lugs onthe underside of top tube and down tube. He tells us that Mercian catalogue he has does mention Super Bi-laminated on all lugs with 3" extensions under all tubes

Left
is a Nervex
box which will hold a complete set of lugs.
Some builders could well stock 50+ boxes of each type of lug.
The Professional though was by far the most popular.
When
the market collapsed in the fifties obviously many builders were left
with lots of these lugs which is why they were available until quite
recently. Even now the odd set surface to the delight of the
lucky
purchaser. Below
is what the builder found when he opened the box
ready to start the build - compare the edges of the lugs with the
carefully filed edges created by a skilled frame-builder: